Method and apparatus for reducing ores



July 15, 1952 'r. SWANN METHOD AND APPARATUS FOR REDUCING ORES 4 Sheets-Sheet 1 Filed April 11, 1951 INVENTOR. 77/000l? ill/MN BY v HITOf/VE x's y 15, 1952 r. SWANN 2,603,561

METHOD AND APPARATUS FOR REDUCING ORES 1 11611 April 11, 1951 4 Sheets-Sheet 2 y 1952 "r. SWANN 2,603,561

METHOD AND APPARATUS FOR REDUCING ORES Filed April 11, 1951 4 Sheets-Sheet 3 METHOD AND APPARATUS FOR REDUCING ORES Filed April 11, 1951 4 Sheets-Sheet 4 II II Z6 '1 za INVENTOR.

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Patented July 15, 1952 7 1 STATES PATENT ,{oFFrcE I QIHMETHOD AND APHSEIETSUSEORBEDUQING :Theodore. Swann, Birmingham Ala. Application April11, ssns arNagzzmses This invention" relates to 5 amethod and apparatus for reducing ores and has for an object to provide :such a method in--whichthe burden is heated indirectly through aheat transferwall in a furnace and in which the sensible heat from the combustion; chamber is utilized to Dre-heat the air for useingas burners in the combustion chamber and also to pre-heat the ore burden.

A furtherobjectof my invention is to provide I I a method and apparatus of the character designated in which carbon-monoxide released from duped into a spirally moving coiumno f the same, v While passing'fthe reducing -gases released from the reduction chamber countercurrent to, and in intimate contact ovith' the burden prior to, the

' entry of the burdeninto the reduction chamber. A further object oi 'my inven tion is to provide a v 19 Claims. (01.: 75-40) charge; end; of the;mreheating pgrtion of the -apparatus; v

Fig; 4 is a-sectional; view' taken along the line 'IV-IV of Fig. 2; and,

- Fig. 5 is a sectional' view taken along theline V -V of Fig. 1, I Referring now to the drawing for a better --;understanding ofmy invention, 1 show a smelting furnace indicated generally by the-numeral ID. The smelting furnace comprises a reducing chamber H and a-combustionchamberpositionedabovethe reducing chamber, The reduc- -ing; chamber-preferably has a graphite inner ----lining l3- to-provide an even distribution of the heatwithin;-the-chan ber. Outwardly of the -;graphit --1ining' I3 is a-layer-of carbon 14 'for heat storage: Surrounding the layer of carbon i4 is a layer of refractory material l liand surrounding the-refractory material I 6 is an outer 2Q-layer of insulation materiall'lr- The; reduction chamber H is-providedwith athin arch shaped roof- I 8" of-silicon carbide or other suitable re- -;fractory whiclrseparates it from the combustion chamb Pre ra rii e s l c a b e r is 5 approximately "or an inch in thickness in its ---thinsections thus pr ovidingfor the maximum transfer of heat between; the combustion chamher and the burden withinthe-reduction chamber. AdJacent' one end of the smelting furnace Ill apparatus ro redu in ,ore'inswhich the om 1 a d mm i hs he; lo o t of 'tion chamber is separat j irom;the iifeduction the reducingichamber; I] is agrun out trough l9 hamber' y a thi 're lafitfii wal ith s sfo -re vi hemqlt rm t k ,A cf br'nm tinga'better transfer oi heajtbetwe h e ch fl t W hes s q n i h m r H the usual a-b v. 'i I j .i. 1 J p h le 2.01mi? S ae.r ,r -o t trou h 1 A sti l, s t ro iect of y i ent o is 'ln n t .w thi eim r orti of he edu Y id pparatusfirmdufl e n wh c i Ore f burden is continuously f'introduce'd ,into the reduc tion chamber th ugh aiecentraliyj disposed chamber surrounding i'thecentrally' disposed ,conduit for passing the products. of. combustion countercurrent t0 and out of directcontactwith the e. combustion cham r 2 i i d w an archeshaped rooj spacedirom the silicon ,car-

1 I e r Bend is' nedwith th .h em

ture refractory material liih The vcombustion moving burden. I s V chamber. also hasan outerjcovering of insulation Apparatusforcarryin'gjfiout myqimprov op :5, H H I 'LJ;- Extendingdojwnwardly through the ess and; which also. illust ates the const ucti com u tionchamb randthesrooi I 8 is..a;conduit features of my invention is shown inftheaccom- *2;3 for introducingghebnrden into the. reduction panying drawings forminga pa it, ofithisi-aiipl cham e ;.w ten nsiinward yfromea h sides of 'n ic g m the combustion chamber jand longitudinally Fig.1isadiagrammaticelevational v'i'ew of the 5Q spaced iron ach othgr are m mj of b fapparatusipartlybrokenjawayiand in section; 24 forburninga suitable hydrocarbon fueljsuch j Fig." 21S anen er dielevatio l v w ofvithe I1 aysrgasi Qpmmunigatm with gas burner-$124 -feed end of the preheating portion oi. the 'appavinglreguiating a e. ue 1 1.51 i iu islzi lha ratus partly brokenaway'and in section; va1 e '21.1th erein-,

., .isan ar' i t 11 2 55 Alsocommunicating with the combustion products of combustion therefrom. The conduit 23 communicates with a pre-heater 29 of any approved design which pre-heats the air supplied to the burners 24. Air is forced through the preheater 29 by means of a blower 30 and passes from the preheater through a conduit 35 and thence through suitable branch conduits 35a to the burners 24. Air regulating valves 40 regulate the supply of air to the burners.

Mounted above the smelting furnace I6 is a combined heat exchanger and conveyer 3| which comprises a rotary cylindrical tube 32 having rigidly secured therein an archimedian screw 33. The screw has flights 34 on a pitch of approximately 6 inches thus permitting the material conveyed by the screw to be mixed and dropped twice for each foot of travel. Staggered openings or slits 36 are provided in the flights for a purpose to be discussed hereinafter.

Surrounding the cylindrical tube 32 is a second tube 31. Extending longitudinally between the tubes 32 and 31 and joined thereto are a plu-' rality of radial fins 38 defining flue ducts 39. The tube 31 is supported from the tube 32 by means of channel members 4|. Surrounding the cylindrical tube 31 is a layer of insulation material 42 which is incased by-an outer wall .43 thus practically eliminating all loss of heat by radiin Figs. 1 and 4. Each roller 46 is supported by a shaft 41 which is rotatably mounted in a suitable bearing 48.

The unit 3| is rotated by means of a sprocket 49 which surrounds one end of the unit. The

sprocket 49 is voperably connected to a motor through a chain 52 andareduction gear unit 53.

At each end of theheat exchangerand conveyer unit 3|, the cylindrical tube 32 and the screw 33 extend past the end of the cylindrical:

tube 31 and the portion of the unit 3| outwardly of the tube 31. Surrounding the tube 32 and spaced outwardly from the end of the tube 31 oppositethe free end of the unit 3| is a layer of insulating material 56 incased by a cylindrical wall 51 having inturned ends 58 and 59.

I Surrounding the discharge end of the unit 3| at the point the tube 31 terminates is a stationary housing member .54, which slidably engages and extends between the, outer surfaces of the walls 43and '51. Secured to each' side of the housing 54 by means of bolts 6| is a gland 60 with suitable packing material 62. The packing material, which may be asbestos or equivalent, provides an air tight joint between the housing and the walls 43 and 51. Communicating with the bottom of the housing 54 is the conduit 28 which conveys the products of combustion from the combustion chamber 2. From the above description of the housing assembly 54 it will be out of direct contact with, the materials conveyed by the screw 33. V

Incasing the discharge end of the screw .33 is a '63 is a gland member 64, with suitable packing material 65 which provides a sealed connection between the housing and the wall 51. Communicating with the outer wall of the housing 63 is the conduit 22 which communicates with the reduction chamber The gases from the reduction chamber pass through the openings 36 in the screw conveyor in a direction countercurrent to the flow ofthe burden thus permitting the burden to be intimately mixed with the gases. Also communicating with the housing 63 through the bottom thereof is the conduit 23 which discharges the burden directly into the reducing chamber from the end of the screw 33.

Surrounding the feed end of the heat exchanger wall 43 and the outer surface of the tube 32 as at 61. Secured to each side of the housing 66 by means of bolts 68 is a gland member 69, similar to the gland members 60 and 64 and including suitable packing material 10. Communicating with the housing member 66 is a conduit 15 which in turn communicates with an exhaust fan 1| for discharging the products 'of combustion.

Incasing thefeed end of the tube 32 and slidably engaging the outer surface thereof is a housing member 12. Secured to the inner sides of the housing 12 by means of bolts 13 is a gland member 14 having suitable packing materialBll which provides a seal between the housing 12 and the tube 32. Communicating with the housing 12 is a conduit 16 which is in turn connected to an exhaust fan 11. The exhaust fan 11 communicates with the conduit 26 by means of a conduit 18 having a regulating valve 19 therein, thus conveying the unused reducing gases to the combustion chamber to be burned therein.

Mounted adjacent the feed end of the unit 3| is a feed hopper 8| which communicates with the tube 32 bymeansof a conduit 82. The conduit 82 extends through the housing member 12 and discharges the burden'into the tube 32 as at 85. A vibrating feeder 83 is mounted adjacent the bottom of the hopper 8| to provide an uninterrupted supply of the burden to the conduit 32. Inasmuch as the construction and operation'of such feeders are well known, no detailed description thereof is deemed necessary.

From the foregoing description of my improved Y apparatus, the carrying out of my improved process may be readily understood. In preparingrthe burden, the ore to be reduced, carbon and'a suitable flux are crushed to a fineness of approximately 8 mesh and mixed together. To prepare aniron ore burden, I mix the iron ore with carbon, such'as coke or lignite char,and a flux such as calcined dolomite. The mixture of iron ore, carbon and flux is then cemented together with Portland cement, as a binder, and

crushed to a particle size of approximately of an inch thus providing a smallsize burden most intimately mixed, each piece containing its own ore, carbon and flux. The crushed particles are then passed over'a inch screen and the second "stationary housing assembly 63 which fines returned to be mixed'with more ore, carban and flux. 7

The burden is placed in the hopper 8| where'it is conveyed by means of the vibrating feeder 83 to the interior of thetube 32. .The heat exchanger and conveyer 3|. is rotated by the motor 5| thus causing the burden to be moved toward the discharge end of the screw 33. 1 Y

I The products of combustion leave the comthe reduction chamber 1600" For just before it has reached the sticky .for the reduction of ores. arch roof of silicon carbide, the transfer of heat $1.5 bustion chamber [lat a temperatureprapproximatel 3,000 F. and pass through the :conduit 28 to the pro-heater "29 thus preheating the air which issupplied to the burners 24. Inthe pre- ;heater 29 the temperature of the combustion pass throughthe flue ducts 39 defined by the radially extending fins 38. As the:combustion gases pass through the unit-3| ina direction counter-current to the movement of the burden practically all-of the remaining sensible heatin the combustion gases is utilized torpreheatthe burden. I

The carbon monoxide and-carbon dioxide' gases which are liberated in the-reduction chamber H and not -used for reduction in the reduction chamber are conveyed through-conduitf22 to the housing member 63. The gases then pass through the tube 32 in a directioncountercurrentto the flow of the burden thus partiallyzreducing and preheating the burdentherein. As the gases pass over the conduit 23 a smallamount thereof is blown down the conduit thereby preventing a back flow'of ,gases through the conduit. I

As the burden is-conve'yed by the'archimedian screw 33 through the. tube 32 it is mixed and dropped through the hot reducing gases twice for each foot of travel, thus reducingferric oxide tomagnetic oxide of iron, where iron ore is used. The preheated partially reduced ore then enters II at approximately stage. When iron ore is employedgthe preheated partially reduced ore is almost in the form of sponge iron-by the time it reaches the reduction chamber II. If desired, thesupply of carbon monoxide and the temperature within the tube 32 may be increased so 'asto reduce the burden to sponge iron by the time it reaches the discharge '4 end of the screw conveyer .33. The :carbon monoxide needed for. increasing thereductionmay be supplied by passing the :spent reducing gases, released from the tube 32, over a hot bed of coke thereby regenerating carbon monoxide. About half of the reduction takes place outside of the furnace thereby greatly reducing the cost of reduction.

i From the foregoing it will be'apparent that I have devised animprovedmethod and apparatus By providing a thin from the combustion chamber :to the burden inside the reduction chamber is-greatlyincreased, thus making it possible to heat the burden indirectly. The graphite lining l3 'aidsin heat 'dis-' tribution and the .layer of carbon l4 stores heat to provide better temperature control.

The CO and CO2 gases liberated from the carbon in the burden, .are'not diluted with tons of air as is the case in the blast furnace. Also, the CO and CO2 gases are employed to partially reduce and preheat the burden before it enters .the reductionichamber. By reducing the ore with carbon monoxide, which results-in aslight gain in heat, I have provided a more economical method of reducing ores than the methods which employ carbon or hydrogen, inwhich-heat must be supplied to keep the reaction going; "If reduction of theiron oxide is by hydrogen there "=wil1'be a small absorption of heat, with carbon a large absorption of heat, but with carbon monoxide the reactionlisv exothermic and there 'is.a smallevolution of heat. i

It will alsoybe seen from the foregoing description of my metho'd and apparatus, that the temperature at which reduction takes place can be veryaccurately controlled thereby permitting selectivereductionoibres. r

"While I have only described the reduction of iron :ore burdens in the foregoing specification,

itwill be apparent' thatother oreburdens maybe reduced. For example, a burdencompr ising phosiphate' rock, carbon and a- 'suitable 'flux may be employed. ..Also, ores :c'onta'ining several metals :may' b'e reduced by form, it will be obvious to those skilled in the art that vit is not so limited, but is susceptible'of various changesand modifications without departing from the spirit thereof, and Idesire-itherefore that only such limitations shall be placed thereupon -as are specificallyzset forth in the apcomprises 'forming a 'bur'den consistingof the oxides to be reduced, carbon -and a flux into a spirally'moving column of the same, introducing said burden into intimate 'co'ntactwith carbon monoxide gas in a 'closedchamber, heating said closedchamber to] maintain the oxides and gas therein within the temperature range required means "of 'a'hydrocarbon fuel 'andjpassing the products of combustion in a direction "countercurrent to and out ofdirect contactwith said spirally moving 'f'column thereby preheating the burden. p

'3. Themet-hodof reducing iox'idesjof ore as defined in claim .2 in which-the products of combu'stion preheat the air vfor combustion prior t preheating said spirally moving column. 4. The method of reducing oxides of ore as defined in'claim2 in whichtheburd'en employed comprises phosphate rock, carbon and a suitable tact with said spirally moving column thus partially reducing and preheating the oxides, and passing the products of combustion from said hydrocarbon fuel'in adirection countercurrent to and out of direct contact with said spirallymoving column thus pre-hea-tingthe burden.

6. The method of reducing oxides {of "iron as 'de'finedin claim 5 in-which a portion'of the burden is; removed in the "form or sponge iron at'the point. said burdenis introduced into the closed 7; The method of reducingoxides of iron as defined in claim which includes the further step of passing'the spentv reducing gases over a bed of hot coke thus regenerating carbon monoxide.

8. In apparatus'for reducing oxidesof ore, a

reduction chamber, a combustion chamber, ad-

jacent to andin heat transfer-relation to the reduction chamber and separated therefrom by 'a thin refractorygwall, means, introducing the. ore to be; reduced, carbon andfiux into the reduction chamber, .meansconveyinga portion of the gases released: in the reduction chamber. in a direction countercurrent :to: and into intimate contact with the burden prior to introducing the.

reduction chamber, a combustion chamber adjacent the reduction chamber heating indirectly said reduction chamber, means introducing a spirally moving burden comprising the. ore to be reduced,- carbon and afiux into said reduction chamber; means conveying the gases released in the reduction chamber and not utilized for reduction therein in a direction countercurrent to and in intimatecontact with said spirally moving burden thereby partially reducing and aiding in preheatingsaid burden, and means conveying the products of combustion from the combustion chamber in a direction countercurrent to and out of direct contact with said moving burden thus further. preheating the burden.

10. In apparatusfor reducing'oxides of ore, a smelting furnace comprising an outer wall of insulation material, a Wall of refractory material adjacent said outerfwall, a combustion chamber in the upper portion of-the smelting furnace, means supplying fuel to. said combustion chamber, a reduction chamber in the lower portion of said furnace, a thin'refractory wall separating the combustion chamber from the reduction chamber, means introducing a burden comprising the ore to 'be reduced, carbonand a flux at. the top 'of said reduction chamber, means conveying a portion of the gases released in said reduction chamber in a direction countercurrent to and into intimateicontact with the burden prior to introducing the burden'into the reduction chamber, and means conveying the combustion gases in a direction countercurrent to and out of direct contact with said burden thereby preheating the burden.

11. Apparatus for reducing oxides of ore-as defined in claim 10 in which fuel is supplied to the combustion chamber by means of a plurality of gas burners extending inwardly of said combustion chamber from the sides thereof.

12. Apparatus as defined in claim 10 in which the gases released from the reduction chamber are burned inthe combustion chamber after passing in intimate contact with the burden.

. 13. In' apparatusfor. reducing oxides of ore including a combined heat exchanger and conveyor unit inthe form of a cylindrical tube having a screw conveyor,. non-rotatably mounted therein and means for rotating the tube, thecombination of a second concentric cylindrical; tube larger in diameter and rigidly secure dto said first. menchamber adjacent the reduction chamber and separated therefrom by Fa thin refractory wall, means for burning a hydrocarbon fuel in said combustion chamber, means introducing a burden comprising the ore to be reduced, carbon and a flux at the feed end of said screw conveyor, a conduit conveying said burden from the discharge end of said screw-conveyer to the reduction chamber, a conduit conveyinggases released from the reductionchamber 'to the discharge end of said firstmentionedwtube; a rotary seal between said conduit conveying the gases from'the reduction .chamber to the discharge end of said first mentioned tube, a conduit conveying the combustion gases from the combustion chamber to the space defined between s'aid first' and second mentioned tubes, a rotary seal between said conduit for the combustion gases and the outer wall of the heat exchanger and conveyer unit, means to remove the gasesfrom the first mentioned tube adjacent the feed end of said unit, and means to remove the combustion" gases from said unit inwardly of the .point the gases are removed from the first mentioned tube. v i

14. 'Apparatus'as defined in claim 13 in which the means introducing the burden at the feed end of the screw conveyer comprises a hopper, a vibrating feeder mounted adjacent the lower end of said hopper and a conduit conveying the burden from said hopper to the screw conveyer. 15. Apparatus as defined in claim 13 which th means to remove the gases'from the first mentioned tube comprises a housing surrounding said tube, a packing gland between said tube and the housing and a discharge conduit communicatin with said housing. I

16. Apparatus as defined in claim 13 in which the means to remove the combustion gases from the-heat exchanger and conveyer unit comprises a housingsurrounding said second mentioned tube adjacent the feed end of said unit, a packing glandbetween the housing and the outer surface of said unit, a second packing gland between the housing andthe outer surface of said first mentioned tube and a dischargeconduit communicating withsaid housing.

17.,Apparatus as defined in claim 13 in which the rotary seal between the conduit conveying the gases from the reduction chamber and the discharge end of said first mentioned tube comprises a housing communicating with'said conduit conveying the gases from the reduction chamber and surrounding the discharge end of said first mentioned tube, and apacking gland between said housing andzthe first menti'oned'tube.

18. Apparatus as defined in claim 13 in which the rotary seal ,between the conduit for the combustion gases and atheouter wall of the heat exchanger and conveyer unit comprise, a housing communicating with the conduit from the combustionchamber and surrounding said unit adjacent the end;of' said second mentioned tube oposite the feedend of'the unit, a packing gland between said housing and the outer wall of the 1.111117, and'asecond packing gland between the housing and the" outer surface of the first mentioned tube. V v 19. In apparatus for reducing oxides of ore includinga combinedheatexchanger and conveyer in'the form of a cylindrical tube having a helical conveyer -non-rotatably mounted therein and means fonrotating the tube, the combination of a reduction ,chamber,;a combustion chamber adjacent the reduction chamber and separated tiqneagtujbe, a! fg u fiqn qhampegla co bustion a therefrom by a thin refractory (wall, means for burning a hydrocarbon fuel in said combustion chamber, a second concentric cylindrical tube spaced from and rigidly secured to said first mentioned tube by longitudinally extending radial fins,- means introducing a burden comprising the ore to be reduced, carbon and a flux into the feed end of said first mentioned tube, a. conduit conveying said burden from the discharge end of said helical conveyer to said reduction chamber, a conduit conveying excess reduction gases from the reduction chamber to v the discharge end of said first mentioned tube, and a conduit conveying the. combustion gases from the combustion chamber to the space defined between said first and second mentioned cylindrical tubes.

THEODORE SWANN.

REFERENCES CITED UNITED STATES PATENTS 10 Number Name Date 233,568 Southan Oct. 19, 1880 1,452,627 Thornhill Apr. 24, 1923 1,904,548 Schultze Apr. 18, 1933 1,920,379 Greene Aug. 1, 1933 

1. THE METHOD OF REDUCING OXIDES OF ORE WHICH COMPRISES FORMING A BURDEN CONSISTING OF THE OXIDES TO BE REDUCED, CARBON AND A FLUX INTO A SPIRALLY MOVING COLUMN OF THE SAME, INTRODUCING SAID BURDEN INTO INTIMATE CONTACT WITH CARBON MONOXIDE GAS IN A CLOSED CHAMBER, HEATING SAID CLOSED CHAMBER TO MAINTAIN THE OXIDES AND GAS THEREIN WITHIN THE TEMPERATURE RANGE REQUIRED FOR REDUCTION, PASSING EXCESS CARBON MONOXIDE GAS FORMED IN SAID CLOSED CHAMBER COUNTERCURRENT TO AND INTO INTIMATE CONTACT WITH SAID SPIRALLY MOVING BURDEN THUS PARTIALLY REDUCING AND PREHEATING THE ORES PRIOR TO REACHING SAID CLOSED CHAMBER. 